Combination packaging structure,trouble light and replacement head lamp



June 1970 H. F. LEVY ETAL 3,51

COMBINATION PACKAGING STRUCTURE, TROUBLE LIGHT AND REPLACEMENT HEAD LAMP Filed June 27, 1967 2 Sheets-Sheet 1 Fl .2 1 66 76 I MIL-3| G 62 ggfl l M ISE- 55 22 46 39 m; 50 52 h] 38 i 43 2? 1| e g 42 Inventors 88 83 U Harold F. Levy 75 Leonard D. Levy 39 56 e7 /79 65 3 rwwk Attorney June 2, 1970 H. F. LEVY ETAL 3,515,354

COMBINATION PACKAGING STRUCTURE, TROUBLE LIGHT AND REPLACEMENT HEAD LAMP Filed June 27, 1967 2 Sheets-Sheet 3 FIG.8

I03 I07 III 370 lOl I04 l4 7, lnentors Harold F. Levy Leonard D. Levy Attorney United States Patent 3,515,864 COMBINATION PACKAGING STRUCTURE, TROUBLE LIGHT AND REPLACEMENT HEAD LAMP Harold F. Levy, 8111 N. Keating Ave., Skokie, Ill. 60076, and Leonard D. Levy, 6555 W. Addison $1., Chicago, Ill. 60634 Filed June 27, 1967, Ser. No. 649,332 Int. Cl. F21v 19/02 U.S. Cl. 240-442 9 Claims ABSTRACT OF THE DISCLOSURE A packaging structure comprising an outer carton with a snug fitting insert, the insert having a pair of axially aligned openings in opposite walls. A deformable headlight-embracing holder is positioned within the insert and has oppositely extending lugs tightly fitting into the respective openings in the insert to secure the headlight to prevent damage in shipment. They further serve as a pivot for the headlamp which may be focused by tilting on the intended work area. The holder is removable from the insert to release the headlamp which may be used as a replacement for a burned out headlight.

BACKGROUND OF THE INVENTION To our knowledge, there has never been heretofore any arrangement of elements which not only function as an eifective package but also wherein the package also serves as a support for the lamp when it is used as a trouble light, the package having parts which snugly and safely hold the lamp in the package from damage and these same parts being used to focus the lamp on the work area.

SUMMARY OF THE INVENTION This invention relates to a combination packaging structure and trouble light and more specifically to a construction wherein the packaging not only serves to protect the headlight while in transit, but also as a support for the light so that it may be focused on the work area and wherein the packaging is readily disassembled to free the headlight if it is intended to use it as a replacement for one burned out.

The invention comprehends novel packaging of the type described which is adaptable to modern assembly line production.

A further object is to provide a novel structure comprising an outer carton and a lamp-mounting inner structure insertable snugly into the carton and provided with handholds to facilitate removal thereof from the carton and handling when used as a trouble-light.

The invention further contemplates a novel arrangement of the holder for interlocking the lamp in the insert to space the lamp from the sides of the carton and also as an adjustable mounting for the light and also as an interlock for maintaining the holder in embracing relation to the lamp.

More specifically, the invention contemplates a cubical carton and a four-sided support made of cardboard and having a pair of circular openings in opposite side walls spaced between the upper and lower edges of said side walls, the Openings admitting lugs formed on a pair of top and bottom cardboard flats, the bottom flat having an opening therein admitting the lens of the lamp therethrough and being smaller than the bead formed at the juncture between the lens and reflector and the upper flat having an opening therein admitting the conical reflector portion therethrough and embracing the bead with the bottom flat, each flat having a pair of lugs of a width substantially equal to the diameter of the enclosing supice port and the lugs fitting into these openings which serve as pivot means with the lugs and the margins of these openings holding the lugs together and thus securing the flats in engagement with the lamp.

These and other objects and advantages inherent in and encompassing the invention will become more readily apparent from the specification and the drawings, wherein:

FIG. 1 is an exploded perspective view of my novel structure partly broken away and shown in section;

FIG. 2 is a sectional view taken substantially on line 22 of FIG. 3;

FIG. 3 is a cross-sectional view taken essentially on line 33 of FIG. 2;

FIG. 4 is an opened plan view of the lamp holder element;

FIGS. 5-9 illustrate a modification;

FIG. 5 being a perspective view;

FIG. 6 being an enlarged sectional view taken substantially on line 6-6 of FIG. 5;

FIG. 7 being a transverse view taken substantially on line 77 of FIG. 6;

FIG. 8 being an unfolded rear view of the lamp holder, and

FIG. 9 being a front View of the holder in folded position.

DESCRIPTION OF THE INVENTION Referring to FIGS. 14, the cardboard carton 2 is of generally cubical form and has four sides 3, 4, 5 and 6, a closed bottom 7 of usual form and a foldable four flap top closure structure 8.

A square or quadrilateral reinforcing insert or support 10 having four side walls 11, 12, 13 and 14 is provided with a corner angle 15 (FIG. 1) which is preferably glued across the juncture of the free edges of the sides 11, 14 of the continuous or one piece of cardboard forming the support 10.

In the side walls 11, 13 there are formed a pair of coaxial transverse circular openings 17, 18 (FIG. 1) which admit lugs 19, 20 of a center portion 23 of a holder generally designated 25 (FIG. 4) which has a center portion forming the plate 23 which is provided with a center opening 26 for admitting the lens portion 27 of a head-lamp 28.

At opposite edges of the center portion these are pairs of spaced striations or scores 30, 31 and 32, 33 (FIG. 4) which facilitate bending of the cardboard to form end walls 35, 36 which hinge to the end sections 37, 38 which have lug portions 22', 22" admitted into opening 18 and 21', 21" admitted into opening 17.

These sections 37, 38 are each provided with semicircular cutouts 38', 39 (FIG. 4) in the remote edges 41, 42 of the element 25 and these cutouts together form a circular aperture admitting therethrough the rear focal cone or reflector portion 43 (FIG. 1) of the headlamp 28. The sections 37, 38 are notched at 44, 45 and 46 (FIG. 3) which admit the alignment lugs 47, 48 and 49 formed on the back side 50 of the rim or head 51 joining the lens 27 with the reflector 43.

The rim or bead 51 (FIG. 2) seats on its front side 52 against the interior side 53 of the panel 23 about the opening 26 while the back side 50 is engaged by the interior sides 55, 56 of portions 37, 38 of panel 24 whereby the lamp is held securely therebetween.

The side edges 57, 58 of portion 23 are provided with the beforementioned lugs 19, 20 and the lugs 23, 24 are formed by half-section portions 21, '21" and 22', 22".

It will be observed as best seen in FIG. 1 that the companion lugs 19, 20 as well as 21', 21", 22 and 22" have considerable thickness extending from the center of the respective opening. Thus they wedge against the marginal edge of the respective opening and at the same time hold the plates 23, 37, 38 in embracing relation to the bead 51.

In the packaged position the external sides 60 and 61 (FIG. 2) of wall portions 35, 36 seat against the internal sides 62, '63 of the side walls 12, 14 of the support and in the position shown in FIG. 2 where the headlamp is used as a trouble light, the opposite corners 64, 65 or 66, 67 (depending upon the direction of tilt of the lamp) engage the respective sides 62, 63 of the support with attendant distortion of the corner formation and/or the outer support 10 while the lugs pivot in the openings 17 and 18.

Thus the headlamp is positionable at desired locations while the support 10 rests upon any of the external sides 70, 71, 72 or 73 (FIG. 3) of the side Walls 11, 12, 13 and 14 or upon either of the end edges 75, 76.

The support 10 is provided in two opposite walls 12 and 14 with handhold slots 77, 78 to facilitate withdrawal of the structure from the carton.

The side walls 12 and 14 are provided with arcuate cutouts 79, 80 extending inwardly from the edge 75. These cutouts are provided to admit the hand of the user to alternately push against the external side of panel 23 whereby to pivot the lamp and holder assembly in focusing it on the intended work area such. as, for example, a wheel with a flat tire. These cutouts 79, 80 also pass the light through to permit high angle tilt of the lamp up or down.

The assembly of the holder with the headlamp proceeds by laying the lens 27 (FIG. 2) in opening 26 and then flapping the panel portions 37, 38 behind the reflector 43. Then the support 10 may be placed transversely of the folded holder with the lamp in place and the sides are then wrapped about the holder while inserting the lugs 19-22 of the holder in the respective openings 17, 18.

Thereafter, the corner piece 15 may be glued or otherwise secured about the disconnected corner 81.

The support or insert 10 serves as a reinforcement to the box walls and is inserted endwise as seen in FIG. 1 into the box while the holder supports the headlamp spaced from the sides and ends of the box.

It will be observed in FIG. 2 that a suitable electrical cord 82 is used having a socket 83 to receive the prongs 84, 85 and 86 of the lamp and the other end of the cord has a plug 88 of a type which is insertable into the cigarette lighter socket of an automobile as well known in the art.

DESCRIPTION OF FIGS. 5-9

This embodiment is similar to that previously described and common parts are identified by the same reference numerals.

The support 10 comprises the four side walls 11-14 as well as the pivot openings 17 and 18 in walls 11 and 13. The support 10 as well as the other parts may be made of cardboard or other suitable material or even plastic. Such materials may also be used in the first embodiment and there is no intention to limit this invention to any specific material.

The holder or support 25a (FIG. 8) comprises end sections 37a, 38a and a center section 23. Section 23 has lugs 19 and 20. Lug 20 is admitted with lugs 21', 21" into pivot opening 17 and lugs 22', 22 into opening 18.

The essential difference in this embodiment is in the construction of the end sections 37a, 38a which are slotted at 101, 102 to form laterally spaced generally square sections 103, 104 and 105, 106 (FIG. 8). These sections are scored diagonally at 107, 108, 109 and 110 (FIG. 8) and apertured with elongated slots along the scoring as at 111, 112, 113 and 114.

The outer portions 103a, 104a and 105a, 106w are folded behind the portion 23 as seen in FIG. 6 similar 4 to portions 37, 38 in the previous embodiment behind the headlight 28. The triangular sections or flaps 103b, 104k and 105b, 10617 are disposed about the bead 51 and admit sectors 51a, 51b, 51c, 51d into the slots 111 through 114. If desired these sections 103b, 104b, 105b, 1061) may be taped together if the material from which the lamp mount is made does not hold its formed position as shown in FIGS. 6 and 7. The lug sections 20, 21', 21 may be stapled or otherwise secured together as at 21, and the lugs 19, 22', 22" may be secured together as by staples 22.

Thus it will be seen that the lamp is held by the pivot element in the support and is adjustable. At the limit of pivot of the lamp the edge portions 108, 109 of sections 103, 104 will abut the inner side 62 of wall 12 and the edge portions 110, 111 of sections 105, 106 will bear against the inner side 63 of wall 14.

Thus a novel, effective, simple, inexpensive and ingenious assembly has been disclosed in the several preferred embodiments of the invention.

It is to be understood that various forms of the invention will become apparent to those skilled in the art in view of the foregoing disclosure and therefore the scope of this invention is to be governed only as set forth in the appended claims.

We claim:

1. For use with a headlamp, a package and trouble light assembly comprising a hollow protective support for the headlamp adapted for insertion within an associated box, and a headlamp holder for removably mounting the headlamp to the support, and means tiltably mounting said headlamp holder to said support and providing adjustment of the position of the headlamp upon an intended work area while said support is located upon associated supporting structure, said means comprising opposed interconnected portions embracing the headlamp, said portions having lugs projecting therefrom, and said support having coaxial openings of diameters substantially equal to the width of the lugs and receiving the respective lugs widthwise therein for securing the holder in the support and providing a pivot therefor to accommodate tilting of the holder with the headlamp.

2. The invention according to claim 1 and said holder being disposed within said support, said holder having said portions thereof positioned in front and rear of the headlamp, and said support snugly confining the holder therein for maintaining said portions thereof in holding relation to the headlamp.

3. For use with a headlamp, a package and trouble light assembly comprising a hollow protective support for the headlamp adapted for insertion within an associated box and a headlamp holder for rernovably mounting said headlamp holder to said support and providing adjustment of the position of the headlamp upon an intended work area While said support is located upon the associated supporting structure, and said support being a quadrilateral structure and said holder being disposed within the support, and said holder comprising a pair of plate elements having openings therein of a diameter admitting opposite portions of the headlamp theretbrough, and said plate elements embracing an intervening portion of the headlamp therebetween, and said holder disposed between the ends of the support in transversely spaced relation to the sides of the support.

4. The invention according to claim 1 and said holder being formed of cardboard sheet and having a center portion with a headlamp lens admitting opening therein, and said sheet having intervening wall forming portions at opposite ends of said center portion, said intervening wall portions positionable within and in abutting relation to the support and said sheet having end portions with arcuate headlamp reflector portion admitting cutouts, and said end portions folded generally parallel to said center portion and the intervening wall portions positionable transversely to said center and end portions, and said end and center portions having said outwardly extending lugs.

5. For use with a headlamp, a package and trouble light assembly comprising a hollow protective support for the headlamp adapted for insertion within an associated box and a headlamp holder for removably mounting the headlamp to said support, and means tiltably mounting said headlamp holder to said support and providing adjustment of the position of the headlamp upon the intended work area while said support is located upon the associated supporting structure, and said support being formed of flexible sheet material and comprising a quadrilateral form having a pair of sides with coaxial openings therein spaced from the ends of the support and having front and rear portions, and a headlamp clamped between said portion, and said portion having lugs tightly projected into respective openings and tiltably supporting said holder with the headlamp within said support.

6. For use with a headlamp, a package and trouble light assembly comprising a hollow protective support for the headlamp adapted for insertion within an associated box and a headlamp holder for removably mounting the headlamp to said support, and means tiltably mounting said headlamp holder to said support and providing adjustment of the position of the headlamp upon an intended work area while said support is located upon the associated supporting structure, and said holder comprising an element havingv a center section with an opening therein for admitting the lens area of the headlamp, a pair of lugs extending outwardly from opposite lateral edges of said center section, and said element having end portions including flaps surrounding said headlamp and having slots therein admitting peripheral edge sections of the headlamp therein, said support having pivot openings receiving said lugs.

'7. The invention according to claim 6 and said support having handhold slots at opposite sides thereof for grasping engagement by the user to facilitate withdrawal of the support with the headlamp and holder therein.

8. The invention according to claim 5 and said holder having abutment portions hingedly interconnecting said front and rear portions and abutting the interior of said support and deformable thereagainst attendant to pivoting of the holder for releasably securing the headlamp in adjusted position.

9. The invention according to claim 6 and said end portions of the holder having outer portions including lug sections transversely alignable with respective lugs of the center section and secured thereto and entered into respective pivot openings.

References Cited UNITED STATES PATENTS 3,140,053 7/1964 Lowell 24036 XR 3,309,512 3/1967 Conley et a1 2403 XR 3,351,750 11/1967 Hall 2403 3,378,681 4/1968 Meyer et a1 34036 XR NORTON ANSI-IER, Primary Examiner R. L. MOSES, Assistant Examiner U.S. Cl. X.R. 

